Packet forming apparatus

ABSTRACT

AN APPARATUS FOR MAKING A CONTINUOUS RIBBON OF INTERCONNECTED DISPENSING PACKETS WHICH INCLUDES MEANS FOR FORMING A PLURALITY OF CAVITIES BETWEEN TWO WEBS AND FILLING THE CAVITIES WITH A MATERIAL TO BE DISPENSED, WHEREAFTER THE CAVITIES ARE SEALED AND THE RESULTANT RIBBON IS WOUND BY A WINDING DEVICE ON SUCCESSIVE REELS, EACH CONTAINING A PRESELECTED LENGTH OF THE RIBBON, WITHOUT ANY INTERRUPTION IN THE CONTINUITY OF MANUFACTURE OF THE RIBBON OF INTERCONNECTED PACKETS.

6 Sheets-Sheet 1 l l l i II E Jrlju.. I .I l. -l l I l l l I. l 1

March 16, 1971 5, K CARLJSLE, JR ET Al.

PACKET FORMING APPARATUS Filed March 27, 1968 6 Sheets--SheerI 2 ET AL PACKET .FORMING APPARATUS S. K. CARLISLE. JR..

March 16, 1971 Filed March 27, 1968 zuil PACKET FORMING APPARATUS Filed March 27, 1968 y *A e sheets-sheet s 'lug` lll INVENTO March 16, 1971 s K CARUSLE, JR` ET AL 3,570,214

PACKET FORMING APPARATUS Filed March 27, 1968 6 Sheets-Sheet 4 E? y /f j M W d M5 /if A /Ay y 44,/ L?? Jg@ /MJ i124 MM jdr/71 "1 /f/ Y f77 FMX/5,

March 16, 1971 5 K QARUSLEl JRl ETAL 3,579,24

PACKET FORMING APPARATUS Filed March 27, 1968 6 Sheets-Sheet 5 6l Sheets-Sheet 6 March 16, 1971 Filed March 2'?, 1968 7i/"w 247V Y l1 (fn United States Patent O1 tice 3,570,214 PACKET FORMlNG APPARATUS Sanford K. Carlisle, Jr., Andover, Mass., and George F. Gordon, Nashua, NH., assignors to Diamond Crystal Salt Company Filed Mar. 27, 1968, Ser. No. 716,605 Int. Cl. B651: 9/04, 47/04 U.S. Cl. 53-184 3 Claims ABSTRACT OF THE DISCLOSURE BACKGROUND OF THE INVENTION The use of individual containers or packets for dispensing individual servings of various commodities, such as spices, sugar, salt, pepper, nutritional substitutes, diet supplements, special diets, etc., is in widespread residential, commercial and institutional use. Conventionally, the packets are formed by employing two overlying strips or webs which are provided with cavities therebetween which are yfilled with the desired material and are thereafter sealed and the resultant ribbon is severed at specific intervals corresponding to the spacing of the individual packets therealong. The bulk of cartons containing such individually severed, disposable dispensing packets is relatively large, but has been found convenient for manual distribution of the individual packets at the time of their intended use.

It is frequently desirable to pre-package various related disposable packets in an individual container or kit to provide a sanitary, self-contained individual serving of such items as salt, pepper, napkins, utensils and the like. This practice has been found to provide particular advantages in hospitals for dispensing special diets to patients whereby selected pre-packaged kits can be provided, each containing the prescribed seasonings and/or nutritional substitutes, as well as the prescribed special diet supplements. In the manufacture and assembly of such special kits, a considerable amount of manual labor is required for individually placing each item to be incorporated in the kit in a suitable container or receptacle, which subsequently is wrapped, preferably in a suitable transparent material such as plastic or cellophane.

It has now been found that substantial savings in time and labor can be achieved in the dispensing of the individual disposable packets, as well as in the manufacture of pre-packaged kits, by handling the packets in the form of a continuous ribbon of interconnected packets which are severed from the end of the ribbon at the time of dispensing. A dispensing apparatus of the foregoing type is disclosed in United States application for Letters Patent, Ser. No. 686,487, tiled Nov. 29, 1967, entitled Packet Dispenser, by Sanford K. Carlisle, Jr., and George F. Gordon, and is assigned to the same assignee as `the present invention. A convenient method for providing ribbons of interconnected packets of indefinite lengths is by winding them on reels which can be conveniently inserted in the automatic dispensing apparatus, providing a large comp-act supply of packets which can be readily interchanged, thereby enhancing the flexibility and versatility of the dispensing apparatus.

3,576,214 Patented Mar. 16, 197i A problem associated with the foregoing discovery has been the difficulty of winding the continuous ribbon of interconnected packets on reels without effecting an interruption of the continuity of operation of high speed packet forming machines. The speed of the formation of the ribbon frequently is in excess of feet per minute and any interruption in the operation of such machines occasioned by the winding of the resultant ribbon on reels results in costly machine downtime and substantially reduces the eiiiciency.

In accordance with the present invention, a packet forming apparatus is now provided incorporating a winding device at the output end thereof, which is operative to automatically wind preselected lengths of the continuous ribbon of interconnected packets on successive reels without any interruption in the continuity of operation of the packet forming apparatus and which reels can be readily stored and transported for future use in dispensing apparatuses in which the ribbon is severed during an unwinding thereof from the reel into individual packets.

SUMMARY OF THE INVENTION The foregoing benets and advantages of the present invention are achieved by an apparatus for making a continuous ribbon of interconnected dispensing packets including means for forming a plurality of longitudinallyspaced cavities between a pair of longitudinally-extending webs, and thereafter lling the cavities with a material to be dispensed, after which the ribbon is sealed. A winding device is located downstream from the sealing apparatus, which includes a frame having a turret on which two diametrically disposed arms are mounted, to the end portions of which windup reels are adapted to be drivingly connected for winding the continuous ribbon of interconnected packets thereon. The turret and the reels mounted on the end portions of the arms are intermittently rotated through arcuately-spaced increments between an initial winding position, a normal winding position, a nal winding position and, nally, to a load and unload position at which filled reels are removed and are replaced by empty reels. The rotation of the reels through the several positions is controlled by suitable sensing means for sensing the quantity of ribbon on a reel. When a quantity approaching the preselected amount to be placed on a reel is sensed, a reel in the normal winding position is moved to the nal wind position, and an empty reel is moved from the load-unload position to the initial wind position, while guide means on the framework of the winding device and a guide shoe move from retracted positions to positions adjacent to the core of the empty reel. At the completion of the winding of a preselected quantity of ribbon on the reel in the nal wind position, suitable severing means disposed adjacent `to the guide means are operative to sever the ribbon and to position the end of the severed ribbon in engaging relationship between the guide shoe and around the core of the empty reel to effect uninterrupted winding thereof on the empty reel. In response to the buildup of a preselected amount of ribbon on the empty reel, the guide means and guide shoe are retracted and the turret is rotated to move the reel in the initial wind position to the normal wind position, while the reel in the final wind position is moved to the load-un1oad position for removal and replacement with an empty reel, The switch over from one reel to the next reel is accomplished automatically and without any interruption in the continuity of the operation of the packet forming apparatus.

The invention further contemplates a reel and carton construction ena-bling packing of the rolls of interconnected packets in overlying stacked relationship, facilitating storage and shipment thereof.

3 BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a fragmentary, partly schematic side elevational view of the elements of an apparatus for making a continuous ribbon of interconnected packets which are automatically wound in preselected amounts by a winding device disposed at the output end of the machine;

FIG. 2 is a fragmentary perspective view of a typical ribbon or strip of interconnected packets made by the apparatus comprising the present invention;

FIG. 3 is an elevational view of the rear side of the winding device with the arms and the reels thereon disposed in an initial wind position and final wind position, respectively;

FIG. 4 is a plan View of the winding device shown in FIG. 3;

FIG. 5 is an elevational view of the rear end of the winding device shown in FIG. 3;

FIG. 6 is an elevational view of the front end of the winding device shown in FIG. 3;

FIG. 7 is a transverse vertical sectional view taken through the turret head substantially along the line 7 7 of FIG. 3;

FIG. 8 is an enlarged fragmentary plan View, partly in section, of the mounting hub and reel removably mounted thereon;

FIG. 9 is a fragmentary vertical sectional view of the hub and center portion of the reel shown in FIG. 8;

FIG. 10 is an enlarged transverse sectional view through the upper guide arm taken substantially along the line 10-10 of FIG. 3;

FIG. 11 is a fragmentary vertical sectional view of the release mechanism for the ribbon severing assembly;

FIG. 12 is a plan view of a shipping or storage carton for receiving a roll of the continuous ribbon of interconnected packets after removal from a reel; and

FIG. 13 is a fragmentary side elevational view, partly in section, of the shipping and storage carton shown in FIG. 12 containing a plurality of stacked rolls therein.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now in detail to the drawings, and as may be best seen in FIGS. l and 2, a continuous ribbon or strip of interconnected packets 22 disposed at spaced intervals therealong is conveniently formed, filled, sealed and wound in accordance with the apparatus schematically illustrated in FIG. 1. Each of the packets 22 is defined by a plurality of cavities or fiutes 24, which, in the exemplary embodiment illustrated, consist of four in number, which are separated bp an extended flat section 26 at which the ribbon is adapted to be severed, forming an individual disposable dispensing packet or a multiple of interconnected packets. The continuous ribbon is comprised of two overlying strips or webs, one or both of which are deformed to form the cavities therein which are adapted to be filled with a suitable material to be dispensed and the upper and lower edges of the webs are adapted to be sealed, such as by crimping 28 along the longitudinal edges of the ribbon, forming a secure bond between the overlying webs.

In the schematic arrangement illustrated in FIG. 1, a web 30 is fed over a guide roller 32 and thence through a guide chute 34 between a pair of cooperating rolls 36, 38, which are provided with a plurality of projections and indentations 40, which may be of a substantially semicircular cross section and are disposed conjugate to each other. The projections and indentations 40` are arranged in series separated by elongated fiat portions corresponding to the fiat sections 26 defining the intervening portions between adjacent dispensing packets of the ribbon shown in FIG. 2.

The conjugate meshing relationship between the projections and indentations along the periphery of the rolls 36, 38 imparts a preselected corrugated or tinted pattern to the web 30 which passes around the roll 38` and is placed in firm contact with a second web 42, which is advanced at the same speed around a guide roll 44 and thence around a heated Ibackup roll 46. One or both of the opposed faces of the webs 30` and 42 are provided with a suitable heat-softenable adhesive coating, such as polyethylene, for example, which is softened in response to contact with the heated backup roll 46, effecting a tenacious bonding of the two Webs to each other at their points of contact. The resultant composite ribbon 48 passes upwardly from the bight of the rolls 38 and 46 and passes around a guide roller 50, from which it is twisted or oriented in a vertical position and the lower edge thereof is crimped and heat sealed by means of a sealing roller 52.

The composite strip thereafter is advanced beneath a filler hopper 54, from which a curtainous stream of a suitable material, such as salt, pepper or the like, is dispensed downwardly and into the open upper ends of the flutes formed in the composite ribbon. Upon passage beyond the filler hopper 54, the upper longitudinal edge of the composite filled ribbon is heat sealed and crimped by a sealing roller 56, whereafter the continuous ribbon of interconnected dispensing packets 20* is advanced into a winding device `58 and preselected amounts thereof are wound successively on reels 60a, 60b rotatably and drivingly mounted thereon. The winding of the reel with a preselected quantity or length of the continuous ribbon 20 is accomplished without any interruption in the operation of the forming rolls, sealing rolls and filling apparatus of the packet forming apparatus preceding it.

IIt will be appreciated that a continuous ribbon of interconnected packets of an alternative configuration can be satisfactorily made and wound in accordance with the apparatus comprising the present invention in lieu 0f the exemplary ribbon 120 illustrated in FIG. 2. Regardless of the specific form of the continuous ribbon and the material contained within the interconnected dispensing packets, the advantages of continuity of operation and automatic winding of preselected lengths of the ribbon on successive reels is achieved, facilitating storage of the ribbon and subsequent dispensing thereof as individual packets or interconnected multiples of packets upon a severing of the ribbon during an unwinding of the ribbon from the reel or roll.

The winding device disposed at the output end of the packet forming apparatus is best illustrated in FIGS. 3-6. As shown, the winding device comprises a frame including a platform `62 supported on rollers '64 for facilitating mobility and positioning of the device at an appropriate position adjacent to the output end of the packet forming apparatus. The base may further include a suitable supporting jack `66 for relieving all or a portion of the weight of the apparatus from the rollers to prevent inadvertent movement of the Winder device from a preselected position.

An upright pedestal l681 is mounted on the platform 62 adjacent the rearward end or left-hand end of the platform as viewed in FIG. 3. A pair of upright frame members 70 are secured at their lower ends to the platform 62 and are interconnected by a plate 72' at the upper ends thereof. A pair of transversely spaced mounting plates 74 are affixed to and extend upwardly in transverse spaced relationship from the upper surface of the plate 72 on which an arm and reel drive assembly is rotatably supported. The foregoing framework is enclosed within a suitable housing 76, portions of which have been broken away for the purposes of clarity.

A pair of diametrically disposed arms 78a, 78b are rotatably supported at the upper end of the pedestal 68, on the ends of which the reels 60a, `6011, respectively, are rotatably mounted. The arms 78a, 78b are of a box-shape cross section and are hollow to receive the drive members for rotating the reels in a manner subsequently to be described. A plate 80 defining the inner side of the arms,

as best seen in FIG. 7, is securely fastened to the end of a tubular spindle t82, which is rotatably supported by a plurality of circumferentially-spaced rollers 84 affixed to the upright plates 74 and are disposed with their peripheries in rolling bearing contact on the periphery of the tubular spindle. An annular collar 86 is removably secured to the opposite end of the tubular spindle `87. and is positioned such that the radial edge thereof overlies and is disposed in contact with the outer side edges of the rollers 84 disposed adjacent thereto. Similarly, an annular shoulder `88, formed adjacent to the other en=d of the tubular spindle, overlies the side edges of the rollers 8-4 disposed adjacent thereto, thereby restricting undesired axial movement of the tubular spindle. A driven sprocket 90 is keyed or otherwise aixed to the tubular spindle for effecting a rotation thereof in prescribed arcuate incre ments for the purposes an'd in a manner hereinafter described.

A drive chain 92, as best seen in FIG. 3, is trained around the driven sprocket 90 and extends downwardly within the pedestal and is trained around a drive sprocket 94 aixed to the output shaft of a drive unit 96 incorporating a brake therein for intermittently advancing the drive chain through prescribed increments. One liight of the drive chain 92 is trained around an idler sprocket 918 adjustably mounted within the pedestal for maintaining appropriate tension of the drive chain. The operation of the gear motor drive unit 96 is controlled so as to rotate the arms 78a, 78b through ninety degree increments in a counterclockwise direction, as viewed in FIG. 3, where- -by the arms are disposed in successive substantially horizontal and vertical positions. De-energization of the gear motor drive unit when the appropriate position has been attained is suitably achieved by cam lobes 100, as best seen in FIG. 7, which are provided at ninety degree increments on the collar of the driven sprocket 90 and are adapted to trip a limit switch LS1 at the completion of a ninety degree arcuate advancement of the arms simultaneously effecting an energization of the brake mechanism of the gear motor drive unit to prevent overtravel and to further retain the arms in the appropriate position preparatory to the next advancing movement.

In accordance with the foregoing arrangement, it will be apparent that the reels mounted on the end portions of the arms will be rotated through ninety degree increments between an initial wind position, as illustrated in FIG. 3, in which the reel is disposed at a 3 oclock position, to a normal wind position at which the reel is disposed at a 12 oclock position, to a nal wind position in which the reel is disposed at a 9 oclock position, and finally, at a load-unload position in which the reel is disposed at a 6 oclock position. The several positions of the reel are automatically controlled consistent with the transfer of winding from one reel when it has become fully wound to a next reel in a manner subsequently to be described.

A driving rotation of the reels in a counterclockwise or winding direction, as viewed in FIG. 3, is achieved by torque motors 102a, 10212 for the arms 78a, 78h, respectively. The torque motors 102a, 102b are independently energizable for effecting independent rotation of each reel on the separate arms so as to apply a preselected winding tension to the continuous ri-bbon as it is Wound. The torque motors 10221, 102b, as best seen in FIGS. 3 and 5, are mounted within the pedestal 68 and are provided with drive pulleys 104a, 104b, respectively, which are axially offset from each other. Timing belts 106a, 10617 are drivingly engaged and trained around the drive pulleys 104a, 104b, and extend upwardly and are disposed in driving engaged relationship around driven pulleys 108a, 108b, respectively. The driven pulley 108b is drivingly coupled to a cross shaft 110 which extends through the upper portion of the pedestal and centrally through the tubular spindle and through substantially the midpoint of the arms. The ends of the cross shaft 110 are rotatably supported by bearings 112', as best shown in 6 FIG. 4. A drin/en pulley 114b is affixed to the opposite end of the cross shaft within the arms and a timing belt 116b is engaged and trained therearound and extends within the interior of the arm 78b and is trained around a driven pulley 118b affixed to a hub shaft 120b rotatably supported by bearings 122b at the end thereof.

Similarly, the driven pulley 108a is affixed to a tubular shaft 124 encircling the cross shaft 110 and extends axially through the tubular spindle into the interior of the arms and to the end portion of which a driven pulley 114a is affixed. A timing belt 116a is engaged and trained around the driven pulley 11'4a and extends within the arm 78a and is engaged and trained around a driven pulley 118a affixed to a hub shaft 120a rotatably supported between hub bearings 1'22a at the end portion thereof. As will be best seen in FIG. 7, the tubular shaft 124' is rotatably supported by bearings 126 aixed in the ends of the tubular spindle 82. The foregoing coaxial drive arrangement enables independent rotation of the reels mounted on each of the arms.

The reels are removably mounted on the ends of each arm, as best seen in FIG. 8, by means of a hub 128 of a hexagonal cross section affixed to a disc 130, which in turn is mounted on the hub shaft, such as the hub shaft a. A spring-loaded engaging pawl 132 is adapted to project from the hexagonal surface of the hub 12S and engage an aperture formed in the hub 134 of a reel, such as the reel 60a illustrated in FIGS. 8 and 9. This construction provides for simple removal of the reel by simply depressing the engaging pawls 132 upwardly and in clearance relationship relative to the apertures in the reel hub, enabling sliding movement of the reel off the hub 128 and replacement with an empty reel when the arm is in the load-unload position.

It will also be noted, as best seen in FIG. 9, that the hub portion of the reel is formed with a star-shaped core 136, whereby the crests 138 thereof are adapted to mechanically engage and interlock with the cavities or flutes 24 of a continuous ribbon during the initiation of the winding operation, thereby dispensing with the need of alternative securing means such as tape or the like, for attaching the lead end of the continuous ribbon to the reel core. This feature constitutes a still further advantage of the present apparatus in that upon subsequent unwinding of the continuous ribbon from the reel, the end of the ribbon is simply released, avoiding the imposition of any stresses or undue tension on the continuous ribbon. This construction also enables a roll of the continuous ribbon to be axially withdrawn from the hub of the reel for storage as will subsequently be described in connection with FIGS. 12 and 13. To enable removal of a roll of packets from a wound reel, the reel 60a as shown in FIGS. 8 and 9 is provided with gusset plates 135, which are afxed such as by welding to the core 136 and to each of which an axially extending stud 137 is secured, which project.l through suitable aligned apertures formed in a remov able side 139 of the reel. The removable side of the reel is retained in appropriate assembled relation on the hub, such as by wing nuts 141 threadably engaged on the studs 137 as shown in FIG. 8.

Guidance of the continuous ribbon into winding relationship on a reel is achieved by an upper or guide arm incorporating a cutoff assembly thereon, which is pivotally lconnected to the upper portion of a column 142 mounted on the forward end of the platform 62. The column 1,42 comprises a pair of spaced, upstanding frame `members 144 rigidly secured at their lower ends to the platform. The guidance of a severed end of the continuous ribbon into engagement around the core of an empty reel is achieved by a lower or hitching arm 146, which also is pivotally mounted on the column 142, as may be best seen in FIGS. 3 and 6. The guide arm 140 and the bitching arm 146 are illustrated in FIGS. 3 and 6 in solid lines in a closed position,

which is representative of a condition wherein the reel 60b on the arm 78b, as shown in FIG. 3, is in the final wind position preparatory to the severance of the web or ribbon and an initiation of a winding of the ribbon on the reel 60a disposed on the arm 78a which is disposed in the initial wind position. The guide arm and hitching arm are movable from the closed position, as shown in solid lines in FIG. 3, to an open or normal position, as shown in phantom, which is representative of a normal wind position in which the reel 60a has been moved from the position shown in FIG. 3 in solid lines to the upright vertical position as shown in phantom.

The hitching arm 146, as best seen in FIGS. 3 and 6, is comprised of a plate 148 which is afiixed to the end of a cross shaft 150 extending between the frame members 144 and rotatably supported by end bearings 152. A bellcrank 154 is affixed at substantially the midpoint of the cross shaft 150 and is connected by a link 156 to a double-acting iiuid-actuated cylinder such as a pneumatic cylinder 158. A link 160 extends between the bellcrank 154 and is connected to the end of a bellcrank 162 secured at substantially the midpoint of a tubular cross shaft 164 rotatably supported by bearings 166 at the upper end of the column 142, to the projecting flanged end portion of which the upper guide arm 140 is attached. Accordingly, actuation of the pneumatic cylinder 158 effects simultaneous arcuate movement of the guide arm and bitching arm between the angularly spaced positions such as the closed positions such as the closed and open positions illustrated in FIG. 3.

The hitching arm, when in the open position as shown in phantom in FIG. 3, is in an inoperative or standby position when a reel is in a normal wind position. The hitching arm 146 is moved to the closed or operative position, as shown in solid lines in FIG. 3, preparatory to the transfer of the winding of a continuous ribbon from a reel in the final wind position to an empty reel disposed in the initial wind position. The hitching arm serves the function of guiding the severed end of the ribbon into engagement around the core of an empty reel and, for this purpose, incorporates an arcuate resilient shoe 168 mounted on a finger 170, which in turn is pivotally mounted to the outer end of the plate 148 of the hitching arm. The arcuate shoe 168, as best seen in FIG. 3, is of a curvature so as to progressively approach the crests 138 on the star-shaped core of the reel, effecting an interlocking winding engagement therewith. The opposite end of the finger 170, which is mounted on a pivot bracket 172 is controlled in angular position by the guiding coaction between a guide rod 174 extending through a pivotally mounted collar 176 affixed to the opposite end of the pivot bracket 172. The guide rod 174 and the plate 148 form a parallelogram-type linkage arrangement, effecting an angular movement of the arcuate shoe and finger in response to the pivoting movement of the hitching arm. The pivot bracket 172 is normally biased toward the stop position as shown in FIG. 3 by means of a coil spring 178 overlying the lower end of the guide rod and disposed in biased relationship against the collar 176.

The opposite end of the guide rod 174 is pivotally supported by a collar 180 pivotally secured to a bracket 182 afiixed on the outer surface of the column 142, as best seen in FIG. 6. The upper end of the guide rod 174 as shown in FIG. 3 is also resiliently biased by means of a coil spring 184 extending around the upper end thereof and disposed in bearing biasing contact against the collar 180.

The parallel linkage arrangement of the hitching arm 146 also provides sensing means for determining whether a full reel has inadvertently been left on an arm while in the load-unload position in lieu of its replacement with an empty reel. This is achieved during the movement of a reel from the load-unload position, as shown in FIG. 3 in a counterclockwise direction, whereby the continuous ribbon on a full reel contacts the finger 170, effecting a clockwise rotation thereof beyond the position as illustrated in phantom in FIG. 3, whereupon this movement is operative to trip a suitable sensing device, such as the limit switch LS2 affixed to the plate 146. Alternatively, the limit switch can be mounted so as to be actuated by the reciprocatory movement of the guide rod 174 as desired. The tripping of the limit switch LS2 serves to signal the central control circuit of the presence of a full reel, which is operative to de-energize the winder apparatus and the packet forming apparatus to enable this error to be corrected.

The upper or infeed guide arm 140, as best seen in FIGS. 3, 6, l0 and l1, is comprised of a pair of spaced side plates 186, to the inner of which the tubular cross shaft 164, as best seen in FIG. 6, is affixed. An infeed wheel 188 is affixed on a shaft 190, which extends through the tubular cross shaft 164 and is provided with a grooved periphery, as best seen in FIG. 1l, corresponding to the spacing of the flutes 24 and fiat sections 26 of the packets, as best seen in FIG. 2. A pair of resiliently-biased rollers 192 are disposed in rolling bearing contact against the flat portion of the continuous ribbon, maintaining it in appropriate engaged relationship with the infeed wheel. In accordance with this arrangement, the advancement of the continuous ribbon relative to the infeed wheel effects a rotation thereof with a corresponding rotation of the shaft 190, which in turn extends through to the opposite side of the column 142 and is mechanically connected to a suitable counter mechanism 194. The counter is electrically connected to the central control circuit and is operative upon the winding of a preselected quantity of packets on a reel to effect an appropriate positioning of the arms, as `well as a rotation of the reels between the several positions, to provide for automatic transfer of the winding operation from one reel to the next.

A suitable buffer mechanism is preferably provided between the output end of the packet forming apparatus and infeed ywheel of the winder apparatus to provide sufficient slack in the ribbon to compensate for the rotary movement of the reels between the several positions as well as for absorbing any fluctuations in tension in the ribbon. The mechanism as shown in FIG. 3 consists of a pivotally mounted take-up arm 181, which is biased in a clockwise direction by a tension spring 183 and a snubber spring assembly 185. A spool-shaped guide roller 187 is rotatably mounted on the end of the arm 181. The ribbon 20 is advanced horizontally from the output end of the packet forming apparatus over a guide roll 189 adjustably supported on a bracket arm 191, and then downwardly around the underside of the spool 187 and upwardly into engagement -with the infeed wheel 188.

The continuous ribbon extends from the infeed wheel 188 beneath a guide plate 196 over a smooth guide roller 198 mounted on the forward end portion of a ribbed extension plate 200. The continuous ribbon thereafter passes beneath a series of output guide rollers 202 on a roller bracket 204, as best seen in FIG. 3, and extends therefrom into winding relationship around the core of a reel.

The upper guide arm also incorporates a ribbon or web severing assembly, which is operative to sever the continuous ribbon when prescribed quantity of packets have been wound on a reel disposed in the final wind position and effect a transfer of the winding operation to a next reel disposed in the initial wind position. As best seen in FIG. 3, the severing assembly comprises a lever 206 pivotally mounted at the upper forward portion of the roller bracket 204, which is provided with a severing knife 208 at the forward end thereof. An offset fiat spring 210 is affixed to the lower portion of the lever 206 and serves to position the severed end of the ribbon in engaging contact with the star-shaped core of a reel at the completion of the severing operation. The lever 206 and the knife 208 thereon is movable from a cocked position, as shown in solid lines in FIG. 3, to an uncocked position, as shown in phantom. Movement of the lever and severing knife is achieved by a linkage arrangement including a push rod 212 guidably mounted and extending through an upstanding bracket 214 attached to a pair of parallel spaced side plates 216, which are secured along their lower edges to a spacer bar 218, as best seen in FIG. 10. The push rod 212 is pivotally connected by means of a clevis-type fitting 220 to the lever 206, and at its opposite or forward end by a similar clevis-type fitting 222 to a pivotally mounted arm 224 mounted between the forward ends of the side plates 216. The push rod is resiliently biased toward an uncocked position by means of the biasing force of a coil spring 226 disposed between the bracket 214 and a collar 228 affixed on the push rod.

The lever and push rod of the severing assembly are retained in the cocked position by means of the coaction of a release pawl 230, as best seen in FIGS. 3 and 1l, which is notched and is adapted to engage the lower edge of the arm 224. The release pawl 230 is pivotally mounted between the side plates 216 and is released in response to the upward movement of a release pawl pin 232, which extends between the side plates 216 and is guided Within an upwardly extending slot 234 formed therein. The upward movement of the release pawl pin can be achieved by a suitable solenoid (not shown) which preferably is electrically timed by a suitable photoelectric sensing device or cam to achieve a severing of the web at a point corresponding to the fiat section separating adjoining packets, as best seen in FIG. 2. The upward movement of the release pawl pin effects a counterclockwise rotation of the release pawl, effecting a disengagement of the arm 224, whereupon the coil spring 226 effects a rapid pivoting movement of the lever 206 and the severing knife thereon from the position as shown in solid lines in FIG. 3 to an uncocked position adjacent to the core of a new reel as shown in phantom.

A recocking of the severing assembly is preferably achieved in accordance with the construction as illustrated in the drawings in response tothe movement of the upper guide arm from the closed position to the open or raised position. During the lifting movement of the upper arm, the rearward edge of the severing arm 224 contacts a cocking roller 236 mounted on a transverse brace 238 affixed to the upper end of the column 142. Accordingly, the cocking arm is forced to rotate in a clockwise direction to a position where the release pawl again engages the lower edge portion thereof, maintaining it in the cocked position preparatory to the next severing operation.

The operation of the apparatus will now be described pursuant to the structural features as'hereinbefore discussed. With the apparatus in the position as shown in FIG. 3, the arms 78a, 78b are in a horizontal position and an empty reel 60a is rotating in a counterclockwise direction, as viewed in FIG. 3, with the upper guide arm and the lower hitching arm in a closed position adjacent to the core thereof. In this position, the reel 6011 is in a final wind position and the reel 60m is in an initial wind position. The advancement of the continuous ribbon effects a continuous rotation of the fiuted infeed wheel, which in turn is transmitted to the counter which, upon attaining a preset count corresponding to a substantially complete winding of the reel 6017, is operative to signal the central control circuit, which effects an energization of the solenoid connected to the release pawl pin, whereupon the severing arm 224 (FIG. 1l) is released and whereupon the lever and severing knife 208 move from the position as shown in FIG. 3 in solid lines to the position shown in phantom. During the downward movement of the lever and severing knife, a cutting of the continuous ribbon is effected and the severed end is moved downwardly and in contact with the star-shaped core of the counterclockwise rotating reel 60a. The severed end is guided in a clockwise manner around the star-shaped core by means of the arcuate shoe 168, whereupon an automatic transfer of winding is attained from the full reel to the next empty reel. Concurrently with the severing operation, the counter is reset and initiates a new count of packets being wound on the empty reel 60a. In addition, the torque motor rotating the reel 60b is de-energized. As material builds Igp giliil irle olf/.glie reel 60a, the upper arm will the winding of a prlscribedrirsiiffl 'to the core and upon t increment therearound, is operative either through the counter or a sensinty device such as a'limit switch contacted by the upper gufde arm flog ilrtliinpgooplogrpllecgcuit to retract the arms .from

pen or normal wind position. Alternatively, a suitable time delay relay can be incorporated in the central control circuit for opening the arms a preselected time interval after the severing operation. Accordingly, the pneumatic cylinder is actuated, effecting a movement of the arms from the closed position as shown in solid lines in FIG. 3, to the open position as shown in phantom. During the opening movement of the'upper guide arm, the severing assembly thereon is again cocked preparatory to the next severing operation. At the same time, the drive unit 96 is energized, whereby the arms 78a, 78b are rotated in a counterclockwise dii-ection, as viewed in FIG. 3, through an increment of ninety degrees such that the reel 60a is disposed in a raised position, as illustrated in phantom in FIG. 3, corresponding to the normal wind position. The full reel 6011 in turn is advanced to a lowered position representative of the load-unload position in which it is removed and replaced with an empty reel.

The winding of the continuous ribbon on the reel 60a in the normal wind position continues until the reel becomes almost completely wound and in response to a signal from the counter mechanism, effects a re-energization of the drive unit, effecting a further rotation of the arms 78a, 78b in a counterclockwise direction, whereupon the reel 60a is moved to a position corresponding to the position of the arm 78b as illustrated in solid lines in FIG. 3. At the same time, the arm 7817 having an empty reel thereon is moved from the load-unload position to a position corresponding to the arm 78a as illustrated in solid lines in FIG. 3. Rotation of the arms 78a, 78h stops in response to the tripping of the limit switch LS1 by the lobe 100 on the driven sprocket 90 (FIG. 7), which simultaneously effects energization of the cylinder 158, effecting a movement of the upper guide arm and lower hitching arm from the open position to the closed position as illustrated in FIG. 3. At the same time, the constant torque motor b (FIG. 5) is energized, whereupon the empty reel 60h comences to rotate in a counterclockwise direction at the initial wind position.

Upon the further winding of the continuous ribbon on the full reel 60a, the counter signals the central control system and a severing of the ribbon is effected in a manner as hereinbefore described, whereupon the winding operation is transferred to the empty reel. Upon the completion of the severing operation, a de-energization of the torque motor 1026i is achieved, whereby the fully Wound reel stops rotating preparatory to removal at the load-unload station.

In accordance with the foregoing operation, fully wound reels are successively removed from the winder apparatus at the load-unload station, which can alternatively be stored or shipped in that form or the roll of wound ribbon thereon can be removed from the reel by removing the removable side 139 and the wing nuts 141, as previously described in connection with FIGS. 8 and 9, enabling the roll to be axially removed off the star-shaped hub. The emptied reel can thereafter be re-assembled by attaching the removable reel side 139 to the core and secured in place by the wing nuts and thus be reused on the winder apparatus.

The packaging of the unsupported rolls, indicated at 240 in FIGS. 12 and 13, for storage or shipment can conveniently be achieved by employing a suitable case, such as a disposable carton 242, made of corrugated paperboard. The carton 242 is of a conventional construction and consists of a base panel 246, to which inner iiaps 248 are secured and are in turn adhered or otherwise aflixed to outer tiaps 250. The outer flaps 250 are in turn aiiixed to side panels 252, forming a three-dimensional square enclosure having an inside width corresponding substantially to the diameter of the rolls 240 to be stored therein. Suitable end flaps (not shown) are provided for sealing the carton after it has been filled with rolls.

Maintenance of the continuous ribbon of packets in the form of the roll 240 is achieved by employing one or more corner roll support pieces 254, which are of a triangular coniiguration and may be suitably composed of corrugated paperboard. The corner roll support pieces are positioned with the sides thereof in bearing contact with the vertical side panels of the carton and with the hypotenuse thereof in tangential contact with the periphery of the roll. The center of each roll is suitably supported by means of a square-shaped core support piece 256, which is of a size such that the outer corners thereof are disposed in supporting relationship against the surface of the innermost winding of the continuous ribbon of the roll. The core supporting piece 256 similarly may be composed of a suitable corrugated paperboard and may comprise a separate piece or may be integrally formed in part from the center portion of roll divider plates 258, which are substantially coextensive with the cross section of the carton and are interposed between adjacent rolls as best seen in FIG. 13. The corner roll support pieces 254 and the core support piece 256 are of a height corresponding substantially to the width of the continuous ribbon of packets forming the roll and serve in part to support the weight of superimposed rolls in a filled carton through the intervening roll divider plates. Further support of the core support piece 256 can be achieved by an inner reinforcing member 260', as shown in FIG. 12, providing for further rigidiiication and avoidance of any distortion of the core support piece in reponse `to loads applied thereto.

In accordance with the foregoing arrangement, a plurality of unsupported rolls can be stored indefinitely or be shipped without the reel structure and can then readily be removed from the carton as required and dispensed from the roll as individual or interconnected multiples of packets from a suitable dispensing apparatus. For this purpose, the rolls as removed from the carton can be placed in a suitable rotary magazine from which the outer end of the continuous ribbon can be withdrawn and severed at the desired increments to form the individual packets. Alternatively, the roll can be remounted on a disassemblable reel, such as the reel 60a shown in FIGS. 8 and 9, and unwound in response to the rotation of the reel rotatably supported on a suitable dispensing apparatus.

It will be appreciated that the foregoing construction and method of fabricating, winding, storing and dispensing disposable-type packets provides for a substantial simpliication in the handling and distribution of packets com- 12 prising individual servings of various commodities such as spices, sugar, salt, pepper, etc.

While it will be apparent that the invention herein disclosed is well calculated to fulfill the objects above stated, it will be appreciated that the invention is susceptible to modification, variation and change without departing from the proper scope or fair meaning of the subjoined claims.

What we claim is:

1. An apparatus for making a continuous ribbon of interconnected packets comprising means for forming a plurality of cavities between two overlying webs, means for filling said cavities with a material to be dispensed, means for sealing the material in said cavities forming a continuous ribbon of interconnected dispensing packets, means for continuously `winding said ribbon on a reel in a preselected length, said reel having a core deiining a substantially cylindrical surface formed with a plurality of projections therealong for removably engaging said ribbon along the projecting `surfaces of the cavities therealong delining the individual interconnected packets, means for severing said ribbon when a reel is wound with said preselected length, transfer means for transferring the severed end portion of said ribbon into contact with said Core and interlocking engagement with said projections therearound, and arcuate guide means disposed in a circling relationship around .said core and operable in combination with said transfer means for guiding and retaining said severed end portion in winding engagement with said core during the continued rotation of said reel at least until said severed end portion is disposed beneath the next successive wound layer of said ribbon Without interrupting the continuity of movement of said ribbon.

2. The apparatus as dened in claim 1, wherein said means for continuously Winding said ribbon includes means for determining `when said preselected length has been wound on a reel and means responsive to said last-mentioned means for actuating said means for severing said ribbon.

3. The apparatus as defined in claim 1, wherein said means for continuously winding said ribbon includes supporting means for mounting a plurality of reels in circumferentially-spaced relationship and for intermittently moving said reels in arcuate increments in response to the amount of said ribbon on a reel being wound.

References Cited UNITED STATES .PATENTS 3,295,289 1/1967 Critchell i 53-28 3,323,739 6/1967 Deming 242-56 3,376,687 4/1968 Gewecke 53-180X 3,497,948 4/1970 Weisler et al 53-21X 2,372,072 3/1945 Flaws 53-28X 2,826,020 3/1958 Hoag 53-28 3,409,243 11/ 1968 Wasserlein 242-5 6X TRAVIS S. MCGEHEE, Primary Examiner E. F. DESMOND, Assistant Examiner U.S. Cl. X.R. 242-56 

